Obsolescence Impact on Configuration Management Presented By: Rob Santoro PKMJ Technical Services, Inc.

Definition of Obsolescence Obsolete Equipment - “An item in plant service that is no longer manufactured or are otherwise difficult to procure and qualify.” Source: INPO NX-1037 Revision 1, Obsolescence Program Guideline

Obsolescence in Nuclear What does that mean to Nuclear Power? Manufacturers are no longer making components required to maintain Plant Plants are built with technologies from the 60’s and 70’s License Renewal: How will obsolescence impact the plant for the next 20 years? Average of 20% of installed plant equipment is obsolete

Obsolescence Challenges Existing station workloads make it difficult to allocate resources to support proactive solution development Daily challenges of operating the plant take precedence over Proactive Obsolescence Management Obsolescence Is Not Going Away: Obsolescence is growing by an average of 12,000 models per year

How does Obsolescence Affect Configuration? Design Requirements Physical Configuration Documented It Impacts All Pillars of the Configuration Triangle!

How does Obsolescence Affect Configuration? Documented Configuration: Do you know what in your plant is obsolete? Design Requirements When replacing obsolete components/parts with new ones, will you change the design requirements? Physical Configuration The plant may change when replacing an obsolete item with a new item

Tackling Obsolescence Understand Its Impact Industry Tools Available: Proactive Obsolescence Management System (POMS) RAPID/OIRD Prioritize Challenges Preventive Maintenance Forecaster (PM Forecaster) Obsolescence Manager (OM) Solve Challenges Several Solution Options: Surplus Equivalency Evaluations Design Changes Reverse Engineer Industry Tools Available CMIS

Tackling Obsolescence Understand Its Impact The Industry has adopted POMS to identify obsolescence POMS collects all installed equipment information from each site Every year, all manufacturers of equipment is contacted to identify obsolescence All U.S. Utilities are members of POMS

Understanding Obsolescence Impact POMS Identified: 19% of Data Collected Un-Usable Cannot contact a manufacturer called “%^&:” 15% of Results Incomplete Model number insufficient to determine obsolescence 11% of Results Unidentifiable Manufacturer could not recognize Model Number

Understanding Obsolescence Impact What does this mean to Configuration Management? Incorrect/Missing information in Enterprise Management systems could indicate a gap in Configuration Management

Configuration Challenges Configuration Challenges discovered when trying to understand impact of obsolescence to plant Master Equipment List’s Incomplete/Inaccurate Missing Information Manufacturer Model Number Equipment Details Incomplete Model Number Incomplete Series Number listed Site specific number scheme/code OEM Not Identified AE’s listed as OEM Utility listed as OEM Bill of Materials Incomplete

Addressing Configuration Data Data Clean-Up Review Design Requirements and Physical Configuration to identify what is installed and update Configuration Management Databases Look at: Purchase Orders Work Order History Drawings Vendor Manuals Design Changes Equivalency Evaluations Walk-Down: Review Nameplate data Large Effort Attack in phases: Critical Components first

Data Clean-Up Results: Better data available to identify obsolescence challenges Provides for better planning Some Utilities require Configuration Change Management to modify this information

Configuration Changes Be Cognizant of Obsolescence When Performing Configuration Changes Do not “design-in” obsolescence Digital Equipment Does the OEM have a long term replacement plan? Does my new design implement an obsolete item? Consider Adding a Check in your design process to check for obsolescence before completing design changes

Configuration Changes Post Implementation: Update Data Systems Does your Configuration Change Process require Enterprise Database Updates before Change is complete? Have you updated the Master Equipment List? Have you updated the Bill of Materials? Avoid future obsolescence challenges by clearly documenting current design changes

Configuration Changes When Performing activities that impact configuration due to Obsolescence: Consider a “design once, install many” approach Replace all affected component locations with the same item (when possible) Identify and satisfy “worst case” characteristics when replacing obsolete items across multiple systems

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